Performance Analysis Of Surface Condenser In 525MW
ISSN (Print) : 2319-8613ISSN (Online) : 0975-4024Gaurav Masiwal et al. / International Journal of Engineering and Technology (IJET)Performance Analysis of SurfaceCondenser in 525MW Thermal PowerPlantGaurav Masiwal #1, P.S.Kumar *2, Sumit Chaudhary *3# Operation and Efficiency Department,Steag Operation and Maintenance Company Private Limited (SOMC), Andhra Pradesh, India1masiwalgaurav@gmail.com* Power Plant Professional,Steag Operation and Maintenance Company Private Limited (SOMC), Andhra Pradesh, India2ps.kumar@somc.co.in*Mechanical Department, Delhi Technological University, Delhi, India3mait.sumit@gmail.comAbstract— This paper presents off design performance evaluation and calculation methodology of asurface type condenser. Best condenser pressure which can be achieved in actual off design conditions hasbeen evaluated by real time parameters. Condenser performance study has been carried out for coolingwater flow, cooling water inlet temperature, and for air ingress/dirty tubes. This method can be proveduseful in the case where no curve regarding variation of condenser back pressure verses cooling waterinlet temperature is available. All data for performance has been collected and evaluated from a 525MWoperating unit of Bharat Heavy Electricals Limited.Keyword - Surface Condenser; Heat Transfer; Steam Condenser; Heat Load; Condenser performance; PowerPlantI. INTRODUCTIONThis paper is based on performance analysis of condenser in a 525MW thermal power plant. A thermal powerplant consists of five major components – (1) boiler, (2) steam turbines – high pressure turbine, intermediatepressure turbine and low pressure turbine, (3) condenser, (4) feed water pumps – condensate extraction pumpsand boiler feed pumps, (5) feed water heaters – one feed water heater (steam bled from high pressure turbineexhaust), one feed water heater (steam bled from intermediate pressure turbine) and three feed water heater forwhich steam is bled from low pressure turbine [1]. In boiler, constant pressure heating of feed water takes placein economizer, evaporator and in superheater. Superheated steam then goes to high pressure turbine, expands toproduce work. Some part of steam is extracted here for feed water heating process. Steam then is reheated tohigh temperature and enters in intermediate pressure turbine. Some steam is again bled for regeneration process.Steam then enters in low pressure turbine where again some portion of steam is extracted for feed water heatingprocess. After passing through the low pressure turbine, steam goes to condenser where this steam converts intosaturated water. Low pressure feed water pumps (condensate extraction pumps) pump condensate water to thelow pressure heaters where this condensate water gets some heat from extracted steam. After low pressureheaters, condensate water goes to Deaerator and then with the help of high pressure feed water pumps (boilerfeed pumps) feed water enters the boiler via high pressure heaters. And this way whole cycle repeats itself.Condenser is an essential component in thermal power plant. It is a type of heat exchanger in which steamundergoes phase change by giving latent heat and converts into water. In turn coolant water gains sensible heat.As specific volume of steam is more than that of specific volume of condensed water. A vacuum (negativepressure) develops in shell side of condenser which extracts more steam from low pressure turbine exhaust andthus creates a self suction natural phenomenon. Condenser reduces the turbine exhaust pressure so as to increasethe specific output of turbine. Vikram Haldkar, Abhay kumar sharma, R.K Ranjan, and V.K Bajpai [5] haveworked on performance analysis of a surface type condenser. Rafal Laskowski [6] has analysed steam condenserperformance in off-design conditions as the function of inlet parameters. Sami I. Attia [7] has analyzed theinfluence of condenser cooling water temperature on the thermal efficiency of a nuclear power plant.R.K.Kapooria, S Kumar and K S kasana [8] did technological investigations and efficiency analysis of a steamheat exchange condenser. Ajeet Singh Sikarwar, Devendra Dandotiya and Surendra Kumar Agrawal [9] didperformance analysis of a surface condenser under various operating parameters. Amir vosough, Alireza falahat,Sadegh vosough , Hasan nasr esfehani, Azam behjat and Roya naseri rad [10] has worked on improvement onpower plant efficiency. Said M.A. Ibrahim and Sami I. Attia [11] have analyzed influence of condenser coolingseawater salinity changes on the thermal performance of a nuclear power plant.DOI: 10.21817/ijet/2017/v9i3/1709030186Vol 9 No 3 Jun-Jul 20171931
ISSN (Print) : 2319-8613ISSN (Online) : 0975-4024Gaurav Masiwal et al. / International Journal of Engineering and Technology (IJET)The objective of this paper is to analyze the condenser performance by comparing the actual condenserpressure with calculated condenser pressure. Deviation between actual and calculated condenser pressure hasbeen break-up into three factors- (1) variation due to cooling water inlet temperature, (2) variation due tocooling water flow and (3) variation due to air ingress/dirty tubes. For calculating theoretical condenser pressureheat balance approach across condenser has been used. Net heat load on condenser has been evaluated byconsidering significant heat loads points.II. PLANT DESCRIPTIONThe power plant has a total installed power capacity of 1050MW. The power house consists of two steamturbine unit of 525MW each. The schematic diagram of one 525MW unit is shown in Fig.1. This unit employsreheating and regenerative feed water heating system. Feed water heating is carried out in two stages of highpressure heaters (HPH-6, HPH-5) and three stages of low pressure heaters (LPH-3, LPH-2, LPH-1) along withone deaerating heat exchanger. Steam is superheated to 170 bar and 537 0C in the steam generator and fed to thehigh pressure turbine. The high pressure turbine exhaust then goes to reheater where steam is reheated to 537 0Cand enters to intermediate pressure turbine. Low pressure turbine exhaust is sent to condenser. Condensatecollected in hotwell is extracted and pumped by condensate extraction pumps (CEP) to the low pressure heaters.Feed water after LPH-3 goes to deaerator and then pumped by boiler feed pumps to the high pressure heaters.And thus whole cycle repeats again. Single pass, Surface type shell and tube condenser manufactured by BHELis provided in system. Condenser cooling medium is sea water. For prevention against corrosion and erosion,titanium tubes are provided. Sodium hypochlorite dosing is done at cooling water pump suction to avoid aquaculture and biological growth. Operating conditions of the power plant at 100% load is shown in Table I. Designdetails of condenser are shown in Table II.A. NomenclatureMcCCWTcoTci TUuncorrectedUcorrectedAsurfaceLMTDTTDC.F cw, inlet tempC.F tube materialC.F cleanliness g water mass flow rateSpecific heat capacity of cooling waterCooling waterCooling water exit temperatureCooling water inlet temperatureCooling water temperature riseUncorrected overall heat transfer coefficientCorrected overall heat transfer coefficientHeat transfer surface area of condenserLogarithmic mean temperature differenceTerminal temperature differenceCorrection factor for cooling water inlet temperatureCorrection factor for condenser tube materialCorrection factor for foulingSaturation temperature of steamSaturation pressure of steamEnthalpyMain steamFeed waterBoiler feed pumpSuperheaterReheaterStator currentHP turbine exhaustReheated steamPower generationTurbine driven boiler feed pumpDOI: 10.21817/ijet/2017/v9i3/1709030186Vol 9 No 3 Jun-Jul 20171932
ISSN (Print) : 2319-8613ISSN (Online) : 0975-4024Gaurav Masiwal et al. / International Journal of Engineering and Technology (IJET)Fig.1. Schematic diagram of power plant.Table I. Design Conditions of Power Plant at 100% Load with 0% Make UpS.NoOperating Condition at 100% Load (0% make up)Value1Power output (MW)5252Main steam flow (kg/s)4363Main steam pressure (bar)1704oMain steam temperature ( C)5375Reheater flow (kg/s)3906Reheated steam pressure (bar)7oReheated steam temperature ( C)8Feed water flow (kg/s)40.43537436o9Feed water inlet temperature to boiler ( C)253.4Table II. Design Details of CondenserS.No1Design DetailsValueNumber of passes1323Cooling water flow (m /s)Surface area of condenser (m2)4Cooling water inlet temperature (oC)52420627.432oCooling water temperature rise ( C)7o678910Terminal temperature difference (TTD)-( C)Log mean temperature difference (LMTD)-(oC)Specific heat capacity of sea water- (kJ/kg-oC)Density of sea cooling water (kg/m3)Cleanliness factor6.469.53.88310470.911Condenser pressure (bar)0.098DOI: 10.21817/ijet/2017/v9i3/1709030186Vol 9 No 3 Jun-Jul 20171933
ISSN (Print) : 2319-8613ISSN (Online) : 0975-4024Gaurav Masiwal et al. / International Journal of Engineering and Technology (IJET)III.CALCULATION METHODOLOGYApplying first law of thermodynamics, energy balance for the condenser can be made.Net heat load on condenser Heat gained by cooling water.Net heat load on condenser Mc * C * (Tco – Tci)(1)The heat load on condenser is from the following sources: - Heat added to main steam, heat added inreheating, heat addition to feed water due to friction in boiler feed pump, heat addition due to superheater spray,heat addition due to reheater spray. Governing equation for heat addition due to different sources is given inTable III. Net heat load on condenser at different loading conditions is shown in Table IV.(2)Net heat load on condenser Ucorrected * Asurface * LMTDUcorrected Uuncorrected * C.Fcw, inlet temp * C.F tube material * C.F cleanliness factor. [2](3)Table III. Equations for Calculation of Net Heat Load on Condenser.S.NoParametersEquations1Heat added by main steam (kJ/s)HMS mms*(hMS-hFW)2Heat added by reheated steam (kJ/s)HHRH mhrh*(hHRH-hCRH)34Heat added by boiler feed pump(kJ/s)Heat added by superheater spray(kJ/s)HBFP mfw*(hBFP,out-hBFP,in)HSH spray mSH spray*(hMS-hSH spray)5Heat added by reheater spray (kJ/s)HRH spray m RH spray *(hHRH-hRH spray)6Stator current losses (kJ/s)HS.C (Iarmature )2 * Rarmature7Power generation losses (kJ/s)Pgen loss 0.1% Pgen Hmech loss H iron loss H stator loss8Net heat load on condenser (kJ/s)Hnet load HMS HHRH HBFP HSH spray HRH spray – Pgen - Pgenloss.Saturation temperature (Tsat) can be derived from Log mean temperature difference expression in thefollowing manner. Temperature profiles of hot and cold fluids are shown in Fig. 2. in which steam is condensingat saturation temperature (Tsat) and cooling water enters at Tci and exit at Tco.LMTD ( Ti - To)/Ln ( Ti/ To)(4) Ti Tsat - Tci(5) To Tsat - Tco(6)Tco-Tci T(7)LMTD [(Tsat - Tci) – (Tsat - Tco)]/Ln [(Tsat - Tci)/ (Tsat - Tco)](8)LMTD [Tsat - Tci – Tsat Tco]/Ln [(Tsat - Tci)/ (Tsat - Tco)](9)LMTD [Tco - Tci]/Ln [(Tsat - Tci)/ (Tsat - Tco)](10)LMTD T/ Ln [(Tsat - Tci)/ (Tsat - Tco)](11)Ln [(Tsat - Tci)/ (Tsat - Tco)] T/ LMTD(12)Let T/ LMTD X(13)Ln [(Tsat - Tci)/ (Tsat - Tco)] X(14)x[(Tsat - Tci)/ (Tsat - Tco)] e(15)Tsat - Tci ex *(Tsat - Tco)(16)Tsat [Tco*(ex) - Tci] / (ex -1)(17)DOI: 10.21817/ijet/2017/v9i3/1709030186Vol 9 No 3 Jun-Jul 20171934
ISSN (Print) : 2319-8613ISSN (Online) : 0975-4024Gaurav Masiwal et al. / International Journal of Engineering and Technology (IJET)Table IV. Net Condenser Heat Load at Various Loading ConditionsParametersMS Flow(kg/s)MS press(bar)MS temp(oC)RH flow(kg/s)HRH press(bar)HRH temp(oC)CRH press(bar)CRH temp(oC)FW flow(kg/s)Final FWpress afterHP heaters(bar)Final FWtemp atECO inlet(oC)TDBFPFWsuctionpress (bar)TDBFPFWsuctiontemp (oC)TDBFPFWdischargepress (bar)TDBFPFWdischargetemp (oC)RH spray(kg/s)RH spraypress bar)RH spraytemp (oC)SH spray(kg/s)SH spraypress (bar)SH spraytemp (oC)Voltage(kV)Load 2222DOI: 10.21817/ijet/2017/v9i3/1709030186Vol 9 No 3 Jun-Jul 20171935
ISSN (Print) : 2319-8613ISSN (Online) : 0975-4024PowerfactorGaurav Masiwal et al. / International Journal of Engineering and Technology 00.9700.9700.960CW inletaverage(oC)293030313130303130303030CW heat 90620618664916701733698874689430Table V. Break-up of Deviation of Actual and Calculated Condenser PressureParametersLoad ndenserpressure 0.1020.1020.102Actual T (oC)7.47.77.97.47.69.07.98.28.28.68.68.7Inlet coolingwatertemperaturecorrection 51.0661.0651.066Corrected Heattransfercoefficient(KW/m2- 0LMTD temperature .5Calculated/target condenserpressure 0.0930.0930.094Theoretical al TTD(oC)3.44.23.94.64.95.24.55.64.65.25.05.3B.P due to CWinlet 70.0870.0800.0850.0830.085DOI: 10.21817/ijet/2017/v9i3/1709030186Vol 9 No 3 Jun-Jul 20171936
ISSN (Print) : 2319-8613ISSN (Online) : 0975-4024Gaurav Masiwal et al. / International Journal of Engineering and Technology (IJET)B.P due to CWflow and CWinlet 40.0950.0850.0900.0890.092Variation due toCW on due toCW flow 0.0060.0060.007Variation due toair /dirty 0.0140.0120.0130.010TsatTsat Ti Tsat – TCo To Tsat – TCiTCoX (Distance of hot fluid fromentry of heat exchanger)TCiFig. 2 Temperature profiles of hot and cold fluidsSaturation pressure (Psat) corresponding to saturation temperature (Tsat) of steam is termed as calculated/targetcondenser back pressure. Calculated/target condenser pressure at different loading conditions is shown in TableV.IV. RESULT AND DISCUSSIONSThe Deviation of actual condenser pressure from calculated/target condenser pressure is shown in Fig. 4. Thisdeviation is attributed to three main factors – (1) variation due to cooling water inlet temperature and variationdue to cooling water flow as shown in Fig. 3 and (2) variation due to air ingress/dirty tubes as shown in Fig.4.From the results it can be concluded that condenser back pressure improves due to drop in CW inlettemperature when compared to design CW inlet temperature. Variation in condenser back pressure due todeviation in CW inlet temperature will be considered as negative whenever cooling water inlet temperature wouldbe less than the design cooling water inlet temperature. Significant deviation in condenser back pressure isobserved due to lower CW flow than the design; causes for lower CW flow may be poor performance of CWpumps or due to low suction head.More deviation in back pressure due to air ingress or dirty tubes is also observed. It may be due to actual airingress which can be appropriately judged by observing hot well water temperature. It can be noticed that at 366MW load and cooling water inlet temperature of 29 deg C, instead of 0.079 bar back pressure (calculated), theactual condenser pressure is 0.088 bar. This deviation (0.01 bar) between actual condenser back pressure andcalculated condenser back pressure is attributed to three factors.(1) Deviation due to CW inlet temperature is -0.010 bar, (a gain in back pressure), which implies that backpressure can be lowered by 0.010 bar had the cooling water inlet temperature was at 29 deg C, by keepingother parameters constant.DOI: 10.21817/ijet/2017/v9i3/1709030186Vol 9 No 3 Jun-Jul 20171937
ISSN (Print) : 2319-8613ISSN (Online) : 0975-4024Gaurav Masiwal et al. / International Journal of Engineering and Technology (IJET)(2) Deviation due to CW flow is 0.006 bar, a loss in pressure which implies that CW flow is less than designflow, which is indicated by higher cooling water temperature rise through condenser tubes.(3) Major deviation is due to air ingress/dirty tubes. Deviation due to air ingress/dirty tubes as an individualentity shows a 0.014 bar loss of pressure.In case of air ingress, there are methods available for online air ingress testing. But among them, heliumleakage is best as it can be performed online without affecting power generation.Cooling water inlet temperature (deg C) / Variationin condenser pressure (mmHg)353025Cooling water inlet temperature (deg C)20Variation (Gain) in condenser pressure due to cooling water inlet temperature (mmHg)Variation (Loss) in condenser pressure due to cooling water flow (mmHg)151050360370380390400410420430440450Load (MW)460470480490500510520Fig. 3. Deviation of observed condenser pressure from calculated/target condenser pressure due to cooling water inlet temperature andcooling water flow.0.1200.110Condenser pressure (bar)0.1000.0900.0800.070Observed Condenser pressure (bar)0.060Calculated condenser pressure (bar)0.050Variation (Loss) in condenser pressure due to dirty tubes / air ingress 0430440Load (MW)450460470480490500510520Fig. 4. Deviation of observed condenser pressure from calculated/target condenser pressure due to dirty tubes and air ingressing.ACKNOWLEDGMENTThe author is grateful to the management and staff of HNPCL and SOMC for their cooperation and helpfuldiscussions.REFERENCES[1][2]Ankur Geete and A.L. Khandwawala, “Thermodynamic analysis of 120MW thermal power plant with combined effect of constantinlet pressure (124.61bar) and different inlet temperatures”, Elsevier, Case studies in Thermal Engineering 1 (2013) 17-25.Heat Exchange Institute incorporated standards for steam surface condensers, tenth edition.DOI: 10.21817/ijet/2017/v9i3/1709030186Vol 9 No 3 Jun-Jul 20171938
ISSN (Print) : 2319-8613ISSN (Online) : 0975-4024Gaurav Masiwal et al. / International Journal of Engineering and Technology (IJET)[3][4][5]J.P.Holman, Heat Transfer, McGraw-hill (ISBN-10:0-07-844785-2),Eight Edition.A.B.Gill, Power Plant Performance, Elsevier (ISBN-978-1-4831-0000-5), first edition.Vikram Haldkar, Abhay kumar sharma, R.K Ranjan, V.K Bajpai,”Parametric analysis of surface condenser for thermal power plant”,IJTT, Vol.3, No.4, (Dec 2013).[6] Rafal Laskowski,”Relations for steam power plant condenser perfromance in off-design conditions in the function of inlet parametersand those relevant in reference conditions”, Elsevier, Applied thermal engineering 103 (2016) 528-536.[7] Sami I. Attia,”The influence of condenser cooling water temperature on the thermal efficiency of a nuclear power plant”, Elsevier,Annals of nuclear energy (2015), ] R.K.Kapooria, S Kumar and K S kasana,”Technological investigations and efficiency analysis of a steam heat exchange condenser:conceptual design of a hybrid steam condenser”,Journal of energy in Southern Africa, Vol. 19, No.3, August 2008.[9] Ajeet Singh Sikarwar, Devendra Dandotiya, Surendra Kumar Agrawal,”Performance analysis of a surface condenser under variousoperating parameters”, IJERA, Vol.3, Issue 4, Jul-Aug 2013, pp. 416-421.[10] Amir vosough, Alireza falahat, Sadegh vosough , Hasan nasr esfehani, Azam behjat and Roya naseri rad, “Improvement Power plantefficiency with condenser pressure”, IJMSE, Vol. 2, No.3, June 2011.[11] Said M.A. Ibrahim and Sami I. Attia,”Influence of condenser cooling seawater salinity changes on the thermal performance of nuclearpower plant”, Elsevier, Progress in nuclear energy 79 (2015) 115-126.DOI: 10.21817/ijet/2017/v9i3/1709030186Vol 9 No 3 Jun-Jul 20171939
saturated water. Low pressure feed water pumps (condensate extraction pumps) pump condensate water to the low pressure heaters where this condensate water gets some heat from extracted steam. After low pressure heaters, condensate water goes to Deaerator and then with the help of high pressure feed water pumps (boiler
AHT Condenser alarm limit -50 to 120 Condenser temperature alarm limit. Temperature read by T3 probe. ACC Condenser cleaning 0 to 52 weeks When the condenser operation time, in weeks, matches the value from ACC, the disp
AMP condenser AMP condenser AMP condenser AMP condenser drive AMP Cooling # of cores Impedance Gaps/cavity Field gradient Power tube Air cooling 4 cores /gap（2.5-3cmcore） 1k W/gap 以上 1 gaps, 31.25-
Bracket, 1964 Condenser Top Mounting Bracket, 1965-67 Condenser Top Mounting Bracket, 1964-67 Condenser Bottom Mounting Binary Switch, Male Compressor Lead, 13” Hex Bolt, 5/16-18 x 1” Washer, 5/16-18
2) Shell and tube heat exchanger (evaporator) for chilled water production 3) Shell and tube heat exchanger (condenser) for heat rejection in water cooled configuration (alternatively, air cooled condenser can be used, where water is scarce or its use is prohibited) 4) A cooling tower to reject the heat of condenser water
Condenser Specifications XLC 85 CoolWare v7.1.1 Registered To: Johnson Controls - USA - Eric Ramon Customer Name Reference Data 11/9/2007 End User Name Item Condenser Atmospheric Pressure 14.70 psi Project Elevation 0 ft OPERATING CONDITIONS Refrigerant R717 Actual Capacity 84
an air-cooled steam condenser, a preliminary model of a steam plant power converter for the AFR-100 SFR was developed using the GateCycle software. The condenser sizing calculations were done for two conditions on steam side: a reference state at 5 kPa condenser back pressure
4 eco-ATWB - Closed Circuit Cooler eco-ATWB-E - Wet/Dry Closed Circuit Cooler eco-ATWB-H - Wet/Dry Closed Circuit Cooler eco-ATC-A - Wet/Dry Evaporative Condenser eco-ATC-H Wet/Dry Evaporative Condenser PHC - Parallel Hybrid Evaporative Condenser Forced Draft equipment includes the following EVAPCO Product Models: LR Prod
By Franz Bardon (Extracted from “The Practice of Magical Evocation”) . may be used, the same kind of condenser described in "Initiation into Hermetics". It is also possible to use a piece of blotting paper soaked with a liquid condenser instead of a solid condenser, which, after it ha
